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Woo-hoo! My first SgtFang kit! This is going to be fun. This is my first movie-sized helmet, and as many of you know, my first was the Golden Armor Fett kit. It's quite different from the Golden Armor -- much cleaner and the lines are better defined. The kit did have various tiny holes and bubbles -- some in very difficult to acccess areas -- but I believe with patience and my collection of detail metal files, I should be able to bring this up to presentation condition!

I've posted more photos and am doing a more comprehensive write-up on my work on this helmet at:

The thickness of the walls appears irregular. Can anyone advise as to what thickness they should be? I'm going to use Aquamend epoxy putty to build out and neaten this area. Can I just arbitrarily come up with a thickness, e.g. 5 mm.?

The thickness of the walls appears irregular. Can anyone advise as to what thickness they should be? I'm going to use Aquamend epoxy putty to build out and neaten this area. Can I just arbitrarily come up with a thickness, e.g. 5 mm.?

Actually, I'd say you have more to trim away.
If you look along the "wall" edges, you can see a faint mark/line/seam. That's where you should trim down to. Once you get it to that thickness, then use some medium to fine grade sandpaper to even the edges.
Then, on the inside surfaces, you should try to even those out, so when you place a visor inside, it sits pretty flush with the helmet. If there are any little bumps or resin "boogers" on the interior, your visor will be held away from the surface.
Hope that makes sense.

Wow! LOVE those closeup pics! I'll have to start sending people links to this thread when they want better pics from me!

For sanding the back of the visor- if you have access to a bandsaw, take a cheap rubber sanding block from the dollar store, and cut it way down into a miniature copy of itself about 2" x 1". You'll have to cut it so that the rounded side becomes your new sanding surface, and you'll have to cut in new slots for the sandpaper to tuck into, and secure it with little 1/2" furniture tacks.

Perhaps I am not quite envisioning how a bandsaw would be used with respect to the helmet, but I've figured some things out. The material thickness seems to be about 3-4 mm. The vertical portion of the "T" can be done with some dremel and file work, but I might refine it with some Aquamend and sanding.

The horizontal part of the "T' is a different matter. But in the photo below:

... on the top row, the second from the left -- that particular Dremel bit may do the trick.

Question: the ears (near the opening) have this little notch that people say should be levelled off, and that the angle is wrong.

I see some people squaring it off so that it's level with the ground, but that looks "off" to me somehow. I was thinking of making it parallel with the edge of the helmet opening, just like I have it in the last photo I posted.

Thanks, Sarge. It's a great idea. I think I'm just about past that now. The rolled up cardpaper worked out okay. I was able to slip narrow files into the mandibles / cheek plates quite easily to do filing.

Originally, I was thinking to do this as a Concept Fett, since this my first ever, and I want to simply see if I even know how to paint! But seriously, after seeing the metallized treatment to various kits, I'm very drawn to the metallic look. However, a metallic Concept Fett would essentially look like Jango, and the Jango paint scheme is kind of boring to me.

So if I end up not doing this because I need the challenge, then it's very likely it'll be an ESB.

I made this ear "corner" parallel with the rim. I notice some people are instead making it level with the ground, so when you put the ear piece on it, the bevel of the earpiece -- which is parallel with the rim -- conflicts with this ear corner.

Currently I just did a rough Dremelling to this, but I will use Aquamend to build it up properly, then sand it properly.

I'm still working on the cheek corner to square it off. It may require some metal detailing files.